PEX Expanding Tool

ABSTRACT

An expanding tool comprising: an actuator comprising a cylindrical housing that defines an actuator housing cavity; a primary ram disposed within the actuator housing cavity, the primary ram defining an internal primary ram cavity; a secondary ram disposed within the internal primary ram cavity; a cam roller carrier coupled to a distal end of the secondary ram; a drive collar positioned within a distal end of the actuator housing cavity; a roller clutch disposed within an internal cavity defined by an inner surface of the drive collar; a shuttle cam positioned between the roller clutch and a distal end of the primary ram; an expander cone coupled to the primary ram; and an expander head operably coupled to the drive collar.

CROSS REFERENCE TO RELATED APPLICATION

The present application claim priority to U.S. Provisional patentapplication 62/173,730, filed on Jun. 10, 2015, and entitled “PEXExpanding Tool,” which is herein incorporated by reference as if fullyset forth in this description.

BACKGROUND

The present disclosure relates to pipe and tubing expansion tools andmethods. More particularly, the present disclosure relates to PEX(cross-linked polyethylene) expansion tools that utilize a multi-segmentexpansion head, and an auto-rotation feature. Specifically, thepresently described expanding tool comprises an auto-rotation featurethat takes place prior to head expansion.

Polymer tubing is gaining popularity in residential home and commercialbuilding construction due to the rising cost of copper pipe. One of themore common types of polymer tubing is made from cross-linkedpolyethylene, commonly known as PEX. Polymer tubing is connected to ajoint by expanding the mouth of the tubing, thus allowing the tubing toslip over the joint. The tubing is then secured to the joint by crimpingthe expanded part of the tubing. A typical building will have manyjoints; hence installation of the tubing involves expanding the mouthsof numerous tubes.

SUMMARY

The present disclosure describes implementations that relate to a PEXexpanding tool. In

In one embodiment, the disclosure describes a tool operable to expand anend of a pipe. Such a tool may comprise an actuator and an expander headoperably coupled to the actuator the expander head comprising aplurality of expander head segments. When triggered, the actuator firstrotates the expander head and then the actuator expands the expanderhead segments within the expander head.

In an example implementation, the present disclosure describes anexpanding tool. The expanding tool includes: (i) an actuator comprisinga cylindrical housing that defines an actuator housing cavity; (ii) aprimary ram disposed within the actuator housing cavity, the primary ramdefining an internal primary ram cavity; (iii) a secondary ram disposedwithin the internal primary ram cavity; (iv) a cam roller carriercoupled to a distal end of the secondary ram; (v) a drive collarpositioned within a distal end of the actuator housing cavity; (vi) aroller clutch disposed within an internal cavity defined by an innersurface of the drive collar; (vii) a shuttle cam positioned between theroller clutch and a distal end of the primary ram; (viii) an expandercone coupled to the primary ram, and (ix) an expander head operablycoupled to the drive collar.

The features, functions, and advantages can be achieved independently invarious embodiments of the present disclosure or may be combined in yetother embodiments in which further details can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of various component parts of an expandingtool;

FIG. 2 is a cross sectional view of the various components of theexpanding tool illustrated in FIG. 1;

FIG. 3 is a close up view of the motor, the gearcase, and the pump driveof the expanding tool illustrated in FIG. 1;

FIG. 4 is a close-up view of the actuator of the expanding toolillustrated in FIG. 1;

FIG. 5 is a close-up view of various components of the actuatorillustrated in FIG. 4;

FIG. 6 is a close-up view of the shuttle cam illustrated in FIG. 5;

FIG. 7 is a close-up view of the shuttle cam illustrated in FIG. 5;

FIG. 8 is a close-up view of the drive collar of the actuatorillustrated in FIG. 4;

FIG. 9 is another close-up view of the shuttle cam of the actuatorillustrated in FIG. 8;

FIG. 10 is a perspective view of the actuator illustrated in FIG. 9prior to expander head rotation;

FIG. 11 is another perspective view of the actuator illustrated in FIG.10 after expander head rotation and prior to expander head expansion;

FIG. 12 is a perspective view of the expander head of the expander toolillustrated in FIG. 1;

FIG. 13 is another perspective view of the expander head illustrated inFIG. 12;

FIG. 14A is a perspective view of dump valve circuit components that maybe used with an expanding tool, such as the expanding tool illustratedin FIG. 1;

FIG. 14B is a schematic representation of dump valve circuit componentsillustrated in FIG. 14A;

FIG. 15 is a close up view of the primary dump valve of the dump valvecircuit illustrated in FIGS. 14A and 14B;

FIG. 16 is a cross-sectional view of the primary dump valve of theexpanding tool illustrated in FIGS. 14A and 14B;

FIG. 17 is a cross-sectional view of the relief valve of the expandingtool illustrated in in FIGS. 14A and 14B;

FIG. 18 is a close up view of an end of stroke detection components ofthe expanding tool illustrated in FIG. 1;

FIG. 19 illustrates an exemplary method of operating the expander toolillustrated in FIG. 1;

FIG. 20 illustrates a perspective view of the expander tool illustratedin FIG. 1 during a head rotation sequence;

FIG. 21 illustrates a perspective view of the expander tool illustratedin FIG. 20 during a head expansion sequence;

FIG. 22 illustrates a perspective view of the expander tool illustratedin FIG. 21 during a retraction sequence;

FIG. 23 illustrates an exemplary expander tool housing arrangement foruse with an expander tool, such as the expander tool illustrated in FIG.1;

FIG. 24 illustrates a proposed layout of the exemplary expander toolhousing arrangement illustrated in FIG. 23;

FIG. 25 illustrates an alternative actuator for use with an expandingtool, such as the expanding tool illustrated in FIG. 1;

FIG. 26 illustrates the alternative actuator illustrated in FIG. 25; and

FIG. 27 illustrates a shuttle cam that can be used with the alternativeactuator illustrated in FIGS. 25 and 26.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented herein. It will be readily understood that the aspects of thepresent disclosure, as generally described herein, and illustrated inthe figures, can be arranged, substituted, combined, separated, anddesigned in a wide variety of different configurations, all of which areexplicitly contemplated herein.

FIG. 1 is a perspective view of various component parts of an expandertool 10. As illustrated, the expander tool 10 comprises a work end 16and a back end 20. The work end 16 which may also be termed a distal endof the expander tool 10 preferably comprises an expander head 30 that isoperably coupled to an actuator 70. The expander head 30 comprising aplurality of expander head segments 40AF. The actuator 70 comprises agenerally cylindrical housing 74 that is operatively coupled to acylinder body 200. As will be described in greater detail herein, theactuator 70 comprises a number of working components that functiontogether so as to first rotate and then expand the expander headsegments 40A-F within the expander head 30. Mounted to a back end or aproximal end 20 of the cylinder body 200 is a fluid reservoir 230. Thefluid reservoir 230 holds the hydraulic fluid for operating the gearcaseand pump drive. In one preferred arrangement, the fluid reservoir 230comprises a flexible fluid reservoir.

In FIG. 1, a number of components are illustrated as being mounted to anouter surface 202 of the cylinder body 200. For example, near a topportion 204 of the cylinder body 200, a gear case 220, a pump drive 212,and pump drive 210 are directly coupled to the outer surface of thecylinder body 200. The pump drive 212 operates the pump 210. Operativelycoupled to the gear case 220, the pump drive 212, and the pump 210combination is a motor 194. Also operatively coupled to a bottom portion206 of the outer surface 202 of the cylinder body 200 is a pressuresensor 240, a pilot valve solenoid 300, and a position sensor 250, theform and function of which will be described in greater detail herein.

FIG. 2 is a cross sectional view of the various components of theexpanding tool 10 illustrated in FIG. 1. Specifically, FIG. 2 shows theexpanding tool 10 (and its various component parts) in a home position,that is, the position that the expanding tool 10 remains in when it isnot being operated.

FIG. 2 illustrates a cross sectional view of the motor 194, the gearcase 220, the pump 210, the fluid reservoir 230, the cylinder body 200,the actuator 70, and the expander head 30 of the expander tool 10illustrated in FIG. 1. As can be seen from FIG. 2, the actuator 70comprises a number of components that operate the expander head 30 underhydraulic control and operation of the pump 210. Specifically, in thisexample arrangement, the cylinder body 200 is threadedly coupled to theactuator housing 74. The cylinder body 200 defines a cylinder bodycavity 208 and the actuator housing 74 defines an actuator housingcavity 76. Together, the cylinder body cavity 208 and the actuatorhousing cavity 76 contain the various components that operate togetherso as to first rotate the expander head 30 a predetermined amount. Then,after the expander head 30 has been rotated a predetermined amount,these various component parts drive an expander cone 140 into theexpander head 30 so as to expand the expander head segments 40A-F of theexpander head 30 radially outwardly.

The cylinder body cavity 208 and the actuatory housing cavity 76 house aprimary ram 80, a primary ram return spring 88, a secondary ram 100, acam roller carrier 120, a primary ram hard-stop collar 92, a shuttle cam180, a drive collar 160, and a roller clutch 150. The primary ram 80comprises a distal end located near the expander head 30 and a proximalend located near the fluid reservoir 230. At the proximal end of theprimary ram 80, a primary ram flange 86 is provided. In addition, theprimary ram return spring 88 is provided along an external surface ofthe primary ram 80, between the primary ram flange 86 and the proximalor back face of the primary ram hard-stop collar 92.

As illustrated, with the expanding tool in the home position, theprimary ram return spring 88 resides in a non-compressed state. Theprimary ram 80 further defines a primary ram cavity 84 and within thisprimary ram cavity 84 a secondary ram 100 is provided. Similar to theprimary ram 80, the secondary ram 100 comprises a distal end directedtowards the expander head 30 and a proximal end generally directedtowards the fluid reservoir 230. At the proximal end of the secondaryram 100, a secondary ram flange 114 is provided. A secondary ram returnspring 110 is provided along an external surface of the secondary ram100, between the secondary ram flange 114 and an internal primary ramhard stop 94. As illustrated in FIG. 2, with the expanding tool 10residing in the home position, the secondary ram return spring 110 alsoresides in a non-compressed state.

Operatively coupled to the distal end of the secondary ram 100 is thecam roller carrier 120. In one exemplary arrangement, a pin or screw 116may operatively couple the secondary ram 100 to the cam roller carrier120. In this home position, the cam roller carrier 120 resides withinthe distal portion of the secondary ram 100 and also within a distalportion of the primary ram cavity 84. A distal portion of the cam rollercarrier 120 extends into a proximal end of the expander cone 140.

FIG. 3 is a close up view of the motor 194, the gear case 220, the pump210, and the pump drive 212 of the expanding tool 10 illustrated inFIGS. 1 and 2. As illustrated in FIG. 3, the motor 194 is operativelycoupled to a gear housing 224 and this gear housing 224 houses both agearset 222 and the pump drive 210. In one preferred arrangement, themotor 194 comprises a clamshell motor and the gearset 222 comprises atwo-stage planetary gearset. In one example arrangement, the planetarygearset provides fora 10.6:1 reduction.

FIG. 4 is a close-up view of the cylinder body 200 and the actuator 70of the expanding tool 10 illustrated in FIG. 1. Preferably, the cylinderbody 200 comprises an aluminum body comprising a roller-burnished innercavity. A cap side 214 of the cylinder body 200 may be configured tooperate as a fluid reservoir and may be in fluid communication with therear fluid reservoir 230 by way of at least one longitudinal fluidpassage 216.

The secondary ram 100, positioned within the primary ram cavity 84 iscoupled to the cam roller carrier 120. The cam roller carrier 120 isgenerally cylindrical in shape and comprises a cam roller 130 at adistal end 124 of the cam roller carrier 120. This cam roller 130 ispositioned within a slot 142 provided within the expander cone 140 asthe cam roller carrier 120 moves distally and proximally within anexpander cone cavity 144.

The primary ram 80 further comprises a groove 96 along the outer surfaceof the primary ram, located near the proximal end of the primary ram 80.In one preferred arrangement, a magnetic ring 98 is provided within thisgroove 96. As will be discussed in greater detail herein, the magneticring 98 allows an end of stroke detection circuit component (e.g., aposition sensor 250) of the expanding tool 10 to detect when the primaryram 80 reaches a fully retracted position as illustrated in FIG. 4.

In this illustrated arrangement, the secondary ram 100 further comprisesa secondary ram hard stop 112 that is configured as a ridge and providedalong an outer surface 108 of the secondary ram 100. As will bedescribed in greater detail herein, the secondary ram hard stop 112 isconfigured to bear against the internal primary ram hard stop 94 afterthe expander head 30 has been rotated but before expansion of theexpander head 30 is initiated.

In this illustrated arrangement, two set screws 146A,B may be used toaffix the expander cone 140 to the distal end of the primary ram 80.

FIG. 5 is a close-up view of various components of the actuatorillustrated in FIG. 4.

Specifically, FIG. 5 is a close-up view of the various components of theactuator 70 that act togethers so as to first rotate and then expand theexpander head 30. Specifically, FIG. 5 is a close up view of the drivecollar 160, the roller clutch 150, the shuttle cam 180, and the distalend of the primary ram 80.

For example, FIG. 5 illustrates the drive collar 160 as being positionedwithin a distal end 78 of the actuator housing 74. As illustrated, thedistal end 78 of the actuator housing 74 may be provided with anexternal thread 79 for threadedly engaging a cap 24 (shown in FIGS. 1and 2) so as to affix the expander head 30 to the actuator 70. Forexample, reference is made FIGS. 1 and 2 illustrating the cap 24 inthreaded engagement with the distal end 78 of the actuator housing 74 soas to affix the expander head 30 to the expanding tool 10.

The drive collar 160 comprises a first engaging face 164 directed in adistal direction, i.e., towards the expanding head 30. This firstengaging face comprising a plurality of lugs 168 A,B,C,D that aregeometrically configured to match slots provided in the expander headsegments 40 A,B,C,D,E making up the expander head 30. As such, when thedrive collar 160 is rotated prior to expansion of the expander head 30,the plurality of lugs 168A-D transmit torque to the expander head 30,thereby rotating the expander head 30. In one preferred arrangement, theplurality of lugs 168A-D comprise a trapezoidal geometricalconfiguration.

Seated or pressed within an internal cavity 174 defined within an innersurface 172 of the drive collar 160 is the roller clutch 150. The rollerclutch 150 allows drive collar 160 to freewheel on shuttle cam 180 whenthe primary ram 80 is extended in the distal direction. In addition, theroller clutch 150 also transmits torque during retraction of the primaryram 80 in the proximal direction, back towards the home position.

As illustrated in FIG. 5, a groove 170 may be provided along an outersurface 162 of the drive collar 160. Preferably, an o-ring 166 may beprovided in this groove 170 so as to generate enough friction so as toprevent the drive collar 160 from freewheeling on the roller clutch 150.In one preferred arrangement, this o-ring 166 comprises a nitrilebutadiene rubber o-ring.

The shuttle cam 180 is positioned between the roller clutch 150 and thedistal end of the the primary ram 80 and seated along a distal or frontface 93 of the primary ram hard-stop collar 92. Specifically, theshuttle cam 180 rotates around the primary ram 80. A follower bearingthat is attached to the primary ram 80 drives the shuttle cam 180.Extension of the primary ram 80 in the distal direction “resets” theshuttle cam 180 while retraction of the primary ram 80 in the proximaldirection “drives” the shuttle cam 180. In one preferred arrangement,the shuttle cam 180 provides for an approximately 18 degree rotation ofthe expander head 30 for each stroke of the primary ram 80. However, asthose of ordinary skill will recognize, alternative predeterminedrotational configurations may also be used.

Positioned within an internal cavity 184 defined by the shuttle cam 180is the primary ram 80. As noted, the primary ram cavity 84 ends near adistal portion of the primary ram 80 and has a greater diameter at thatend than the remainder of the primary ram cavity. At this largerdiameter cavity, an internal thread 90 is provided. This internal thread90 may be utilized to securely affix the expander cone 140 to theprimary ram 80.

FIG. 6 is a close-up view of the drive collar 160 illustrated in FIG. 5.And FIG. 7 is a close-up view of the shuttle cam 180 illustrated in FIG.5. Specifically, FIG. 7 illustrates a follower bearing 82 of the primaryram 80 pulling through the shuttle cam 180 to rotate the expander head30 during primary ram retraction.

As noted from FIGS. 6 and 7, when the primary ram 80 is transmitted inthe distal direction represented by arrow 134, the shuttle cam 180 andhence the drive collar 160 rotate in the clockwise direction asillustrated by arrow 136. Similarly, when the primary ram 80 isretracted in the proximal direction represented by arrow 138, theshuttle cam 180 but not the drive collar 160 will be rotated in thecounter clockwise direction represented by arrow 139.

FIG. 8 is a close-up view of the drive collar 160 of the actuator 70illustrated in FIG. 4 and FIG. 9 is another close-up view of the shuttlecam 180 of the actuator 70 illustrated in FIG. 7. As illustrated, thecam or slanted or non-axial groove 182 on the shuttle cam 180 is flippedto rotate on primary ram 80 advance where the bearing is replaced with acam roller 130 that is driven by the secondary ram 100. As noted in FIG.9, the expander cone 140 is keyed to the primary ram 80 by way of thecam roller 130 and preferably via two setscrews 146A,B (see, FIG. 4).

FIG. 10 is a perspective view of the actuator 70 illustrated in FIG. 9prior to rotation of expander head 30. As illustrated by arrow 156, thesecondary ram 100 begins to move in the distal direction until thesecondary ram hard stop 112 engages the primary ram internal hard stop94. As the secondary ram 100 proceeds in the distal direction, the drivecollar 160 (and hence the expander head 30 (not shown)) are rotated inthe counterclockwise direction as noted by arrow 154. Once the secondaryram hard stop 112 engages the primary ram internal hard stop 94,expander head 30 rotation is complete and expansion of the expander headsegments 40A-F making up the expander head 30 is initiated. This isillustrated in FIG. 11. For example, FIG. 11 is a perspective view ofthe actuator 70 illustrated in FIG. 10 after expander head 30 rotationand prior to expander head 30 expansion. As illustrated in FIG. 11, thesecondary ram hard stop 112 of the secondary ram 100 has engaged theprimary ram internal hard stop 94, and now, both the primary ram 80 andthe secondary ram 100 will be driven in the distal direction. In thisposition, the secondary ram return spring 110 resides in a compressedstate. Together, the primary ram 80 and the secondary ram 100 drive theexpander cone 140 towards the expander head 30 so as to radially expandthe expander head 30 once rotation is complete.

FIG. 25 illustrates an alternative actuator 770 for use with anexpanding tool, such as the expanding tool 10 illustrated in FIG. 1. Inthis alternative actuator 770, an alternative shuttle cam 780 is used torotate the expanding head segments prior to head expansion.

The actuator 770 operates slightly differently than the actuator 70previously illustrated and discussed. For example, in this alternativeactuator arrangement 770, the shuttle cam 780 moves proximally anddistally along with the primary ram 80. For example, in thisarrangement, the shuttle cam 780 is held in place on the ram 80 by wayof a snap ring 790. Clearance between the shuttle cam 780 and the ram 80allows the shuttle cam 780 to rotate with respect to the primary ram 80.Another difference is that this alternative actuator 770 utilizes theshuttle cam 180 that does not comprise a flange near a proximal end ofthe shuttle cam (see, e.g., FIG. 7 which illustrates the flange along aproximal end of the shuttle cam 180).

FIG. 25 illustrates the drive collar 760 outside of a distal end of theactuator housing after drive collar 760 and shuttle cam 780 rotation hasoccurred. Similar to the drive collar 160 discussed herein, the drivecollar 760 illustrated in FIG. 25 comprises a first engaging facedirected in a distal direction, i.e., towards the expanding head. Thisfirst engaging face comprising a plurality of lugs 768 A,B,C,D that aregeometrically configured to match slots provided in the expander headsegments making up the expander head as previously discussed. As such,when the drive collar 760 is rotated prior to expansion of the expanderhead, the plurality of lugs 768A-D transmit torque to the expander head,thereby rotating the expander head as well. In one preferredarrangement, the plurality of lugs 768A-D comprise a trapezoidalgeometrical configuration.

Similar to the actuator 70 illustrated and discussed herein, seated orpressed within an internal cavity defined within an inner surface of thedrive collar 760 is a roller clutch (see, e.g., FIG. 5 illustratesroller clutch 150). The roller clutch transmits torque during retractionof the primary ram 80 in the proximal direction, back towards a homeposition.

Initially, the shuttle cam 780 is seated within a home positioned,situated between the roller clutch and the distal end of the the primaryram 80. In this home position, the shuttle cam 780 is seated along afront face of the primary ram hard stop as described herein. Prior tohead expansion, the shuttle cam 780 rotates around the primary ram 80. Afollower bearing 782 that is attached to the primary ram 80 drives theshuttle cam 780. Initially, after rotation and as the primary ram 80 istransmitted in the distal direction, the shuttle cam 780, and hence thedrive collar 760, rotate. Depending on the orientation of the cam orgroove 786 provided by the shuttle cam 780, this rotation may either bein counter clock wise or clockwise direction. In the arrangementillustrated in FIG. 25, the orientation of the cam 786 provided by theshuttle cam 780 will produce a clockwise rotation. Alternative cam orgroove arrangements on the shuttle cam may also be used. For example,FIG. 27 illustrates an alternative shuttle cam 781 comprising analternative cam or groove 783 arrangement. In this alternative camarrangement, the orientation of the cam 783 provided by the shuttle cam781 will produce a counter-clockwise orientation prior to headexpansion.

FIG. 26 illustrates the actuator 770 after head expansion and with thefollower bearing 782 retracted to an end position along the cam 786 ofthe shuttle cam 780. For ease of illustration, the follower bearing 782and shuttle cam 780 are illustrated outside of the drive collar 760.Specifically, after head expansion, when the primary ram 80 is retractedin the proximal direction, the shuttle cam 780 (but not the drive collar760) will be rotated in the clockwise direction represented by arrow792. In this manner, the shuttle cam 780 is returned to its original orhome position.

Operation of actuator 770 is generally similar to the operation of theactuator 70 illustrated and discussed herein. For example, prior torotation of an expander head mounted on the expander cone 140, thesecondary ram begins to move in the distal direction until the secondaryram hard stop engages the primary ram internal hard stop. As thesecondary ram proceeds in the distal direction, the expander cone 140(and hence the expander head 30 (not shown in FIGS. 25 and 26) arerotated in the counterclockwise direction as noted by arrow 754 as notedin FIG. 25. Once the secondary ram hard stop engages the primary raminternal hard stop, expander head rotation is complete and expansion ofthe expander head segments making up the expander head is initiated.

Once a full expansion of the expander head has occurred, the primary ram80 is retracted back in the proximal direction, to an original homeposition within the drive collar 760. As the shuttle cam 780 begins toapproach its home position within the drive collar 760, the followerbearing 782 acts on the cam 786 defined by the shuttle cam 780 to turnthe shuttle cam back in the clockwise direction as noted be arrow 792.Again, if an alternative cam or groove arrangement is utilized, thisrotation may by a counter clockwise rotation.

FIG. 12 is a perspective view of the expander head 30 for use with anexpander tool, such as the expander tool 10 illustrated in FIG. 1. Inthis illustrated position, the expander head segments 40 A-F making upthe expander head 30 reside in a closed position. FIG. 13 is anotherperspective view of the expander head 30 illustrated in FIG. 12. In FIG.13, the expander head segments 40 A-F making up the expander head 30reside in a partially expanded state.

As can be seen from FIG. 12, the expander head 30 comprises a pluralityof expander head segments 40A-F. In this illustrated arrangement, theexpander head comprises six expander head segments. However, alternativeconfigurations may also be used.

The expanding tool 10 is configured so that it rotates a predeterminedamount prior to each expansion, the predetermined amount being theamount of rotation needed to move the expanding head segments 40A-F froma tube mouth portion that is stretched to a tube mouth portion that isunstretched. More specifically, the rotation of the expanding headsegments 40A-F is at least partially determined by the number ofexpanding head segments within the expander head 30. The number ofexpanding head segments is selected to allow for multiple rotationswithout repeating the position of the expander head 30. As just oneexample, in one expander tool arrangement, six expanding head segments40A-F are employed with each expanding head segment covering an arclength of 60 degrees. In one preferred expanding tool arrangement, theexpanding tool 10 is configured to rotate the expanding head segments40A-F 18 degrees with each rotation such that 20 rotations are requiredbefore an original expander head 30 position is repeated.

As can be seen from FIG. 12, each expander head segment 40A-F making upthe expander head 30 comprises a bottom surface wherein this bottomsurface comprises a plurality of grooves 32. In a preferred arrangement,these grooves 32 comprise a plurality of trapezoidal grooves that aregeometrically configured to match the plurality of lugs 168 provided onthe drive collar engaging face 164 of the drive collar 160 (see, FIGS. 5and 6). As such, when the drive collar 160 is activated in the clockwisedirection during ram extension, the expander head 30 while engaged tothe drive collar 160 is also rotated a predetermined amount prior toexpander head 30 expansion. These trapezoidal grooves 32 also help guidemovement of the expander head segments 40A-F in the radial direction foran even expansion during head expansion.

As may be seen from FIG. 13, each of the six head segments 40A-Fcomprises an outer surface. As just one example, expander head segment40A comprises an outer surface 42. As illustrated, an outer surface 42Aof the head segment 40A comprises a number of features. For example, theouter surface 42A of the expander head segment 40A comprises pluralityof ribs 44A provided near a distal end 50A of the expander head segment40A. In addition, this outer surface 42A of the expander head segment40A further comprise a first distal groove 46A and a second proximalgroove 48A. In a preferred arrangement, each of the remaining expanderhead elements 40B-F of expander head 30 comprise similar rib and groovearrangements. The ribs 44A are formed near a frustoconical end of theexpander head segments 40A-F and provide a higher frictional forceduring pipe expansion. The first and second groove arrangements 46A and48A may be used with o-rings for enabling segment return after headexpansion. (see, first groove arrangement 46 and second groovearrangement 48 in FIG. 1). In other arrangements, a garter spring mayalso be used for enabling expander head segment return after theexpander head has been expanded. In a preferred arrangement, each of theremaining expander head elements 40B-F of expander head 30 comprisessimilar first and second groove arrangements.

FIG. 14A is a perspective view of a pump and valve system that may beused with an expanding tool, such as the expanding tool illustrated inFIG. 1. As illustrated, this pump and valve system comprises a solenoid300, a pilot valve 340, a relief valve 350, the pump 210, and theprimary valve 390. FIG. 14B is a schematic view of the pump and valvesystem illustrated in FIG. 14A with like elements designated with likereference numbers.

In addition, FIG. 15 illustrates a perspective view of the primary valve390 illustrated in

FIGS. 14A and 14B and FIG. 16 is a cross-sectional view of the primaryvalve 390 of the expanding tool illustrated in FIGS. 14A and 14B. Asnoted in FIG. 15, the primary valve 390 comprises a port or pathconfiguration for controlling fluid flow from and back into the fluidreservoir 230. Specifically, the primary valve 390 comprises a port orpath 392 to the fluid reservoir 230, a port or path 394 to thecylindrical cap, another port or path 396 to the cylinder, and a port orpath 398 to the pump 210.

Referring now to FIGS. 14A-B, 15 and 16, during an expansion sequence,as the primary ram 80 and the secondary ram 100 continue to extend in adistal direction, pressure will build inside the actuator 70. During theexpansion sequence, as the primary ram 80 reaches the primary ramhard-stop collar 92, the pressure within the cylinder body 200 reaches apredetermined transducer setpoint. The pressure sensor 240 will monitorthe pressure within the cylinder body 200. Once the predeterminedtransducer setpoint is reached, the motor 194 will be deactivated. Whenthis setpoint is reached, the valve solenoid 300 is pulsed and this willopen the pilot dump valve 340 to the fluid reservoir 230. Opening up thepilot dump valve 340 also reduces the pressure on the primary valve 390,thereby causing the primary valve 390 to shift states. As fluid from thecylinder body 200 flows through the pilot dump valve 340 back into thefluid reservoir 230, this will reduce the pressure within the cylinderbody 200 and as this internal pressure drops, this will allow theprimary ram return spring 88 to force the primary dump valve 390 toclose.

FIG. 17 illustrates a close up view of the relief valve 350 illustratedin FIGS. 14A and B. As illustrated in FIG. 17, the relief valve 350comprises an o-ring 352, an adjuster plug 354, a relief valve spring356, a poppet 358, and a ball 360. In one preferred arrangement, therelieve valve 350 is configured to allow fluid flow from the actuator 70back into the fluid reservoir 230 in the event that a pressure withinthe actuator 70 exceeds the predetermined setpoint.

FIG. 18 is a close up view of end of stroke detection components of theexpander tool 10 illustrated in FIG. 1. As illustrated, end of strokedetection components comprise a pressure sensor 240. Pressure sensor 240detects full ram extension based upon a pressure within the cylinderbody 200. For example, in one arrangement, pressure sensor 240 willdetect full ram extension once a predetermined pressure setpoint isachieved. In one exemplary arrangement, such a full ram extensionpressure setpoint might be on the order of about 7,000 to about 8,000pounds per square inch (psi). In one preferred arrangement, once thispressure setpoint is detected by the pressure sensor 240, the motor andpump are deactivated. Retraction of both the primary ram 80 and thesecondary ram 100 in the proximal direction is initiated. The pressuresensor 240 may be provided with a pressure connector 246 coupled to thesensor by way of a plurality of wires 244 for connecting to a printedcircuit board provided within the expander tool 10.

A second end of stroke detection component comprises a position sensor250. In one preferred arrangement, such position sensor 250 may take theform of a Hall Effect sensor. Such a position sensor 250 may beconfigured to detect a full ram return to the initial position, such asthe home positions of the primary ram 80 and the secondary ram 100illustrated in FIG. 1. This position sensor 250 enables the motor andpump activation for the next expansion stroke. In one preferredarrangement, the position sensor 250 may be configured to detect themagnetic ring 98 provided within the outer surface groove 96 of theprimary ram 80 (see, FIG. 4).

FIG. 19 illustrates an exemplary method of operating an expander tool,such as the expander tool 10 illustrated in FIG. 1. At step 410, and nowalso referring to FIG. 20, a user input from a trigger starts the motor194 (see, e.g., trigger 620 illustrated in FIG. 23). In a preferredmethod, the motor 194 is electronically locked on if the trigger is heldfor a predetermined period of time. For example, such a predeterminedperiod of time may be greater than one second. One advantage of such atrigger lock on feature is that a user does not have to hold the triggerfor the duration of the stroke. One advantage of such a trigger lock isthat it prevents user fatigue and also allows the user of the expandingtool to support the tool or work piece as needed. In addition, in onearrangement, the trigger lock could also provide a user interrupt ofadvance stroke with an additional trigger pull when the trigger lock isenabled. This would allow the user to abort an expansion if needed.

At step 420, a pressure differential is created across the primary dumpvalve 390 and this pressure differential shifts the primary dump valveshuttle to a closed position. At step 430, fluid is drawn from the rearfluid reservoir 230 and into a pump chamber and then pumped to theactuator 70. At step 440, the secondary ram 100 begins to extend in thedistal direction as fluid is pumped into the actuator 70. As such, thesecondary ram 100 begins to compress the secondary ram return spring110. At step 450, as the secondary ram 100 begins to extend in thedistal direction, the secondary ram 100 also drives the cam rollercarrier 120 in the distal direction, towards the expanding head 30. Assuch, the cam roller 130 is pushed in the distal direction through thecam or groove 182 provided on the shuttle cam 180. At step 460, theshuttle cam 180 rotates in clutch locked direction and transmits torqueto the drive collar 160. At step 470, this torque is transmitted to theexpander head segments 40A-F making up the head 30.

At step 480, the secondary ram hard stop 112 of the secondary ram 100engages the internal primary ram hard stop 94 of the primary ram 80. Forexample, FIG. 21 illustrates a perspective view of the expander tool 10illustrated in FIG. 20 during a head expansion sequence. At step 490,the primary ram 80 continues to extend in a distal direction as pressurecontinued to build inside the actuator 70. At step 500, the expandercone 140 pushes distally into the expander head 30 and against theexpander head segments 40A-F. At step 510, the expander head segments40A-F shift radially outward to expand the expander head out diameter.At step 520, a PEX pipe inner diameter is stretched open.

At step 530, and now referring to FIG. 22 which illustrates aperspective view of the expander tool 10 during an expansion sequence,the primary ram 80 reaches the primary ram hard-stop collar 92, and thepressure within the cylinder body 200 reaches a predetermined transducersetpoint. At step 540, once the predetermined transducer setpoint isreached, the motor 194 is deactivated. As such, motor and user input(i.e., trigger) may be disabled until a full retract of both the primaryram 80 and the secondary ram 100 is sensed, preferably by way of theposition sensor 250. One advantage of such a full return sensing featureis that a user is not able to initiate another expansion stroke untilthe expanding tool is fully retracted. This prevents the user fromoverriding the auto-rotate feature.

At step 550, the valve solenoid 300 is pulsed to open the pilot dumpvalve 340 to the fluid reservoir 230. At step 560, internal pressuredrops and therefore allows the return spring to force the primary dumpvalve 390 to open. At step 570, both the primary ram 80 under a forcecreated by a compressed primary ram return spring 88 and the secondaryram 100 under a force created by a compressed secondary ram returnspring 110 begin to retract. Both primary ram 80 and secondary ram 100move in the proximal direction, back to a home position of the expansiontool 10, as illustrated in FIG. 1.

At step 580, the expander cone 140 is withdrawn from the expander head30, and the expander head segments 40A-F begin to collapse to a closedposition. In one arrangement, collapsing of the expander head segments40A-F may may be aided by way of one or more o-rings provided in thefirst and/or second grooves 46,48 provided in the expander head 30 aspreviously described herein.

At step 590, as the primary ram 80 approaches a fully retracted position(see, FIG. 1), the cam roller 130 pulls through the cam or groove 182provided on the shuttle cam 180. As such, the shuttle cam 180 rotates inclutch freewheel direction so as to reset the actuator 70 for asubsequent expansion.

At step 592, when the primary ram 80 reaches its fully retractedposition or home position, the position sensor 250 detects the magneticring 98 provided in the proximal groove 96 of the primary ram 80. Atstep 594, with the primary ram 80 back in its home position (see, FIG.1), the motor 194 and user input is re-enabled for a subsequentexpansion stroke. As such, when activated, the expanding tool 10 iseither advancing or retracting and a user is not able to hold theexpanding tool 10 in any single expanded position. One advantage of sucha scenario is that a user is prevented from holding the pipe in anexpanded position.

FIG. 23 illustrates an exemplary expander tool housing arrangement 600for use with an expander tool, such as the expander tool 10 illustratedin FIG. 1. In particular, FIG. 23 depicts a tool 600 that is operable toexpand an end of a pipe and that has an advantageous arrangement of thetool handle with respect to the working end of the tool. FIG. 24illustrates a proposed layout of the exemplary expander tool housingarrangement illustrated in FIG. 23.

Referring now to FIGS. 23 and 24, tool 600 includes a working end 608disposed at a distal end 610. This working end 608 includes an expanderhead comprising a plurality of expander head segments 612 as hereindescribed. As previously described, these expander head segments 612 aremovable between a closed position (as illustrated) and an expandedposition. These are also rotatable about the longitudinal axis of thetool 600. The expander head segments 612 may operate in the same orsimilar fashion as the segments 40A-F described above with respect toFIGS. 1-22. In general, the expander head segments 612 may be operableto expand an end of a pipe into which the segments are inserted.Further, in an example embodiment, the tool 600 may be a very largediameter (VLD) expander. Still further, in an example embodiment, thetool 600 may be a hydraulic expanding tool. In particular, the expandingtool 600 may use hydraulics in order to facilitate operation of the tooland expansion of the end of pipes. As mentioned above, tool 600 may beused for expanding an end of PEX pipe. However, tool 600 may also beuseful for other applications as well.

In practice, expanding tools may require a large amount of energy tocreate an amount of inverse torque that will successfully expand a pipesuch as a PEX pipe. Different sized pipes and pipes of differentmaterials may require expanding tools that create different amounts ofinverse torque. In an example, tool 600 is a ten (10) ton compressiontool with a one (1) inch jaw opening. Other examples are possible aswell. For instance, tool 600 may accommodate a number of tons higher orlower that ten (10), and the jaw opening may also be greater than orless than one (1) inch.

The tool 600 further includes a main body 614 connected to the workingend 608. The main body 614 may house tool components, such as internaltool components for facilitating operation of the jaws and hydrauliccomponents. In one preferred arrangement, the main body includes theexpanding tool 10 illustrated and described herein.

Further, the main body 614 includes a handle 616 disposed at a proximalend 518 along the vertical axis of the tool 600. As depicted, the handle616 is configured to be gripped in an orientation that is substantiallyparallel to the longitudinal axis of the tool. The tool 600 furtherincludes a trigger 620 disposed on the handle 616, and the trigger 620is configured to be activated by trigger movement along the verticalaxis of the tool 600. The user may activate the trigger 620 in order toinitiate and/or control operation of the working end 608. In an example,the trigger movement along the vertical axis comprises movement in aproximal direction along the vertical axis. For instance, a user mayactivate the trigger 620 by pulling the user's trigger finger proximallyor down in the vertical direction along the vertical axis of the tool600. In another example, trigger movement may include movement in adifferent direction, such as in a longitudinal direction. For instance,the trigger may be configured to be moved in a distal longitudinaldirection. Other example trigger movements are possible as well.

The tool 600 further includes a hook ring 622 disposed at a distal end624 along the vertical axis of the tool 600. The hook ring 622 may beused for attachment of a carabiner, a lanyard, a sling or some othersimilar device.

The tool further forms a substantially flat surface 630. One advantageof such a flat surface 630 is that it enables bench-top user of theexpanding tool. Another advantage of such a surface 630 is that itallows for second hand placement for vertical riser applications.

In the example depicted in FIG. 23, the trigger 620 is located on alongitudinal proximal side 617 of the handle. However, in otherexamples, the trigger 620 may be located in other positions at or nearthe handle 616, such as the longitudinal distal side of the handle 616.Further, the handle 616 is positioned proximal to the working end 608along the longitudinal axis 604. This proximal placement allows for theworking end 608 to be fully inserted into a pipe without the handle 616causing an obstruction.

In an example embodiment, tool 600 may include one or more additionalsupports (e.g., handle(s)) that provide the user additional ways tosupport the tool. Providing additional support may be helpful to theuser during operation or transport of the tool 600. For instance, tool600 includes a side-handle attachment portion 650 into which the sidehandle 656 can be inserted. FIG. 23 depicts side handle 656 insertedinto the side handle attachment 650. Other additional supports arepossible as well.

The tool 600 further comprises a work light 660 and a lock off switch670.

In an example embodiment, tool 600 may be operated by a single hand ofuser. By being configured to be operated by a single hand of the user,the user may use his or her free hand in order to position and/orstabilize a pipe that is being expanded.

Beneficially, a tool in accordance with the present disclosure offersexample advantages over existing tools for expanding the end of a pipeor tube. For instance, through the unique disclosed orientation of thehandle, the tool 600 offers a user the ability to conveniently operatethe tool in a plurality of orientations and in compact spaces. Asmentioned above, a technician may use tool 600 for repair of pipesand/or installation of pipes, and this repair or installation work mayrequire the technician to work in tight spaces as well as to use thetool in different locations. As particular examples, a technician mayneed to use the tool to install or repair a pipe positioned on thefloor, on a sidewall, or overhead. Further, these pipes may be arrangedin a plurality of different orientations. For instance, the pipe end tobe expanded may be facing vertically downwards, vertically upwards,longitudinally to the left, longitudinally to the right, or at manyother angles.

It may be difficult or not possible to use existing expanding tools insuch a plurality of orientations. However, since tool 600 is configuredto allow the user to operate the tool 600 in a number of different anduseful orientations, a user may use the tool in a variety of situationsand places in which operating existing tools would be difficult or notpossible. For example, the handle orientation in accordance with thedisclosure beneficially allows the user to more easily use—compared toexisting expanding tools—the tool in an overhead position. Additionally,the orientation of the handle may allow a user to more easily support anexpanding tool in the overhead position. A tool such as a ten ton toolmay be heavy and thus difficult to not only position the tool but alsohold and support the tool in place during operation. Tool 600beneficially allows a user to utilize the tool 600 in an overheadorientation without bending or substantially bending the user's wrist.This may allow the user to more comfortably support the tool foroverhead installation or repair work.

Exemplary embodiments have been described above. Those skilled in theart will understand, however, that changes and modifications may be madeto these embodiments without departing from the true scope and spirit ofthe invention. The description of the different advantageous embodimentshas been presented for purposes of illustration and description, and isnot intended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different advantageousembodiments may provide different advantages as compared to otheradvantageous embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

1-24. (canceled)
 25. An actuator for use with a hydraulic toolcomprising: a housing defining a first cavity; a primary ram disposedwithin the first cavity, the primary ram defining a second cavity; asecondary ram disposed within the second cavity of the primary ram; adrive collar positioned at a distal end of the first cavity; and ashuttle cam at a distal end of the primary ram, wherein the shuttle cammoves along with the primary ram.
 26. The actuator of claim 25, whereinthe shuttle cam is coupled to the primary ram such that the shuttle camis suitable to move proximally along with the primary ram.
 27. Theactuator of claim 25, wherein the shuttle cam is coupled to the primaryram such that the shuttle cam is suitable to move distally along withthe primary ram.
 28. The actuator of claim 25, wherein the shuttle camis suitable to rotate relative to the primary ram.
 29. The actuator ofclaim 25, wherein the shuttle cam is operatively coupled to the primaryram by way of a snap ring.
 30. The actuator of claim 25, furthercomprising a roller clutch disposed within an internal cavity defined byan inner surface of the drive collar.
 31. A hydraulic tool comprising: ahousing defining a first cavity; a primary ram disposed within the firstcavity, the primary ram defining a second cavity; a secondary ramdisposed within the second cavity of the primary ram; a drive collarpositioned at a distal end of the first cavity; and a shuttle cam at adistal end of the primary ram, wherein the shuttle cam moves along withthe primary ram, and an expander cone coupled to the primary ram. 32.The hydraulic tool of claim 31, further comprising an expander headoperably coupled to the drive collar.
 33. The hydraulic tool of claim31, further comprising a cam roller carrier coupled to a distal end ofthe secondary ram.
 34. The hydraulic tool of claim 31, wherein theprimary ram comprises a proximal end and a distal end, the primary ramfurther comprising a primary ram flange at the proximal end of theprimary ram.
 35. The hydraulic tool of claim 34, further comprising aprimary ram hard-stop disposed within the first cavity.
 36. Thehydraulic tool of claim 35, wherein a primary ram return spring isprovided along an external surface of the primary ram between theprimary ram flange and a proximal face of the primary ram hard-stop. 37.The hydraulic tool of claim 31, wherein the secondary ram comprises aproximal end and a distal end, wherein the secondary ram includes asecondary ram flange at the proximal end of the secondary ram.
 38. Thehydraulic tool of claim 37, wherein the second cavity of the primary ramcomprises a stepped cavity.
 39. The hydraulic tool of claim 38, whereina secondary ram return spring is provided along an external surface ofthe secondary ram between the secondary ram flange and a step surface ofthe stepped cavity.
 40. A PEX expanding tool comprising, an actuatorcomprising a housing defining a first cavity; a primary ram disposedwithin the first cavity, the primary ram defining a second cavity; asecondary ram disposed within the second cavity of the primary ram; acam roller carrier coupled to a distal end of the secondary ram; a drivecollar positioned at a distal end of the first cavity; a roller clutchdisposed within an internal cavity defined by an inner surface of thedrive collar; a shuttle cam at a distal end of the primary ram, whereinthe shuttle cam moves along with the primary ram, and an expander conecoupled to the primary ram; wherein the secondary ram comprises a ridgethat protrudes outward from an external surface of the secondary ram.41. The PEX expanding tool of claim 40, wherein the first cavitycomprises a primary ram hard-stop, and wherein the shuttle cam is seatedalong a distal face of the primary ram hard-stop.
 42. The PEX expandingtool of claim 40, wherein the roller clutch is suitable to allow thedrive collar to freewheel on the shuttle cam in a first rotarydirection.
 43. The PEX expanding tool of claim 42, wherein the rollerclutch is suitable to allow the shuttle cam to engage and rotate thedrive collar in a second rotary direction opposite the first rotarydirection.
 44. The PEX expanding tool of claim 40, wherein the shuttlecam comprises a slanted groove that defines a cam, and a cam rollerpositioned within, and configured to roll along an internal surface of agroove.
 45. The PEX expanding tool of claim 40, wherein when the PEXexpanding tool is triggered, the secondary ram moves in a distaldirection causing a cam roller to move, causing the shuttle cam and thedrive collar to rotate about the primary ram.